Multi layer weather resistant cover

ABSTRACT

A cover for protecting patio furniture or other objects from adverse weather includes a UV resistant outer layer that may include a top and side panels, an inner layer that may include a top and side panels, and contact sites by which the two layers are fixedly attached to one another. Releasable fasteners for attaching to the furniture or object to be protected are attached to the inner layer. The contact sites are minimal relative to the size of the inner layer, such that the sum of the areas of contact sites or contact areas is substantially less than an unbonded area of the inner layer. Area and perimeter limits apply to the unbonded area between the layers to ensure the two layers can move relatively independent of each other.

FIELD OF THE INVENTION

[0001] This invention relates in general to removable multilayer covers to protect articles from adverse or degrading weather such as wind, rain, sun and snow. It relates more particularly to temporary covers for articles that may be stored outdoors (such as barbecue grills, patio furniture, boats, cars, airplanes, etc.) to be removed when the article is put into use.

BACKGROUND

[0002] Protection of articles stored outdoors, such as patio furniture, barbecue grills, boats, and the like, has been markedly improved by advancements in materials that comprise the tarp or storage cover for the articles. Materials that are both waterproof and breathable aid in shedding rainwater and melting snow or ice, while also dissipating moisture from the immediate environment of the article to prevent mold, mildew and rust. The art is well represented by high performance materials, whether single or multi-ply.

[0003] However, one seemingly inherent drawback to covering articles for outdoor storage is the substantial increase in surface area whereby wind can tip the covered article or blow the cover off of the article. Patio tables are stable in most wind conditions because their frame construction style provides low surface area for winds that generally blow horizontally. These same tables are prone to tip in nominal winds when covered with a broad tarp that acts as a sail over the table's tubular frame.

[0004] What is needed in the art is a temporary covering for articles stored outdoors that is 1) easy to attach and remove, 2) that keeps rain and melting snow off the covered article but allows retained moisture to escape, 3) that is resistant to degradation by the expected weather elements, and 4) that reduces the force of wind on the cover or on the covered article.

SUMMARY OF THE INVENTION

[0005] In accordance with one embodiment of the present invention, a removable cover for protecting an object from exposure to weather comprises an outer layer defining an exterior surface and at least one inner layer defining an interior surface for contacting the object. The inner layer is fixedly attached to the outer layer by at least one contact site such that the inner and outer layers are movable independently of each other except at the at least one contact site. The present invention also includes means for removably securing the cover to the object, the means being attached to the inner layer.

[0006] Another embodiment of the present invention is a removable cover for shielding an object from exposure to weather, including a UV resistant outer layer defining a top outer panel and at least one side outer panel fixedly attached to one another. The cover further includes at least one inner layer that defines a top inner panel having a minor span x and at least one side inner panel. The inner layer is fixedly attached to the outer layer by at least one contact site defining a contact area. The top inner panel includes an unbonded area which is an area free of any contact area. The unbonded area defines an area of at least $\frac{2}{9}\pi \quad x^{2}$

[0007] and is bounded by a perimeter defined by at least one line whose total length is no more than 7.21 πx.

[0008] The present invention also includes a method of covering at least one article of furniture, the method steps including first to provide a cover comprising an outer layer defining an exterior surface, at least one inner layer defining an interior surface for contacting the object, wherein the inner layer is fixedly attached to the outer layer by at least one contact site such that the inner and outer layers are movable independently of each other except at the contact site, and means for removably securing the cover to the object, the means being attached to the inner layer. The final step is to secure the cover to the at least one article of furniture via the means for removably securing that is attached to the inner layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0009]FIG. 1 is a perspective view of the preferred embodiment of the present invention secured to a table, with dashed lines representing an inner layer.

[0010]FIG. 2 is a sectional view taken along line 2-2 of FIG. 1, but depicting different attachment means.

[0011]FIG. 3 is a cross sectional view of a cover according to the present invention secured over a boat.

[0012]FIG. 4 is a perspective view of a cover according to the present invention over a chaise, with dashed lines representing the inner layer.

[0013]FIG. 5 shows a cover according to an alternative embodiment of the present invention in isolation.

[0014]FIG. 6 is a sectional view taken along line 6-6 of FIG. 5, but wherein the inner and outer layers are the same size.

DETAILED DESCRIPTION OF THE PREFERRED AND ALTERNATIVE EMBODIMENTS

[0015] FIGS. 1-2 depict the preferred embodiment of the removable cover 10 of the present invention. Specifically, an outer layer 12 defines an exterior surface 14 for facing the sun, wind, rain, etc, and a top outer panel 16 that is the uppermost discrete panel (where multiple outer panels are used) of the cover 10 as the cover is applied to an object to be protected. The outer layer 12 may also comprise at least one side outer panel 22, joined with the top outer panel 16 at a continuous outer seam 24. Where more than one side outer panel is involved, more than one continuous outer seam may be required. The side outer panel 22 defines an outer layer edge 26.

[0016] The outer layer 12 is preferably breathable, defined herein as having a moisture vapor transmission rate (MVTR) of at least 100.0 g/m²/24 hours. Greater moisture transmission is desirable, and it is preferable that the outer layer have an MVTR of 1000.0 g/m²/24 hours or more. MVTR is also referred to as water vapor transmission rate (WVTR), and may be measured according to ASTM Designation E-96-80, Standard Test Method for Water Vapor Transmission of Materials.

[0017] The outer layer is also preferably UV resistant, defined herein as retaining at least 40.0% (corrected) of its tensile strength after 12 months of exposure to the sun. One appropriate test for UV stability or UV resistance is the “South Florida” test whereby samples with no backing are positioned with the exterior surface 14 facing south and inclined at a 45° angle in the geographic vicinity of Miami, Fla. Tensile strength is measured according to ASTM test D-1682-64. To obtain corrected UV stability, the number of months exposure that yield tensile strength of 50%, 40% and 30%, respectively, of the original (unexposed) tensile strength are added, and the sum is divided by three. Where the latter divided sum is greater than or equal to 12 months, the material is UV resistant as that term is used herein.

[0018] The outer layer should be waterproof, defined herein as resisting water penetration under a hydrostatic head value of at least 30.0 millibars. Hydrostatic head, or hydrohead, is used to determine the resistance of a material to penetration by water under relatively low hydrostatic pressure. Exemplary tests for hydrohead include Federal Test Methods Standard No. 191A, Method 5514; AATCC Test Method 127-89; and INDA Test Method 80-4-92 (modified to include a screen support). The above tests generally apply to non-woven materials, but the outer layer is not necessarily limited to those materials so long as the hydrohead of the outer layer resists water penetration to at least 30.0 mbar. This limitation may be met by the material of the outer layer itself or by a coating applied to the surface of the outer layer that faces opposite the inner layer.

[0019] Adjacent to the outer layer 12 is an inner layer 28, shown in FIG. 1 as dashed lines. Both the outer layer 12 and the inner layer 28 are flaccid and pliable so that they substantially conform to each other. The inner layer 28 defines an interior surface 30 that faces and contacts the object to be covered. Similar to the outer layer 12, the inner layer 28 includes a top inner panel 32 and at least one side inner panel 34 that are joined together at a continuous inner seam 36. The side inner panel 34 also defines an inner layer edge 38. The inner layer 28 need not be the same size or define the same area as the outer layer 12, such as depicted in FIG. 2. The inner layer 28 is durable to protect the outer layer 12 from damage due to friction against stress points 40 on the object 42. Stress points 40 are herein defined as segments wherein the cover 10 rubs against the underlying object 42 causing friction under normal use, such as when the cover 10 is blown by wind. The inner layer 28 may comprise a patch or a plurality of patches attached to the inner layer at expected stress points rather than a continuous layer between the outer layer 12 and every point of contact with the object 42. By example, such an inner layer configured for the table of FIG. 1 would define the shape of a ring. Where the inner layer is one or more patches, the shape and position of the patches forming the inner layer is similarly defined by the shape of the object to be covered.

[0020] Durable is defined herein as resistant to failure by abrasion, and the inner layer should be durable. Abrasion resistance may be measured by ASTM D 3885-99, and a cover according to the present invention should withstand at least 40 cycles to about 300 cycles at a tension load of 2 pounds and a balance head load of 0.5 pounds before failure of the inner layer by abrasion.

[0021] The top inner panel 32 defines a major span 18, which is the length of the longest line across the top inner panel as laid flat. Perpendicular to the major span 18 is a minor span 20, defined herein as the length of a line perpendicular to the major span that spans the top inner panel at its widest point. For a top inner panel in the shape of a circle as in FIGS. 1-2, the minor span 20 and the major span 18 are equal to the diameter of the circle. For a rectangle such as that described below in association with FIG. 4, the longer dimension of the rectangle is the major span 18 and the shorter dimension of the rectangle is the minor span 20. By definition, the minor span 20 can never exceed the major span 18.

[0022] The outer layer 12 and the inner layer 28 are secured together via one or more contact sites 44 that define one or more contact areas. A contact area is defined herein as the surface area within one inch of a contact site 44, a contact site being the actual bonded or fixedly secured portion. This is arbitrarily chosen to readily determine an area and/or perimeter of an unbonded area, detailed below. The contact sites and thus the contact areas may be defined by stitching, ultrasonic bonding, adhesive bonding, thermal bonding, hook and loop fasteners, or any of the various means to attach two layers of fabric or other flaccid material to one another. Where more than one contact area is employed, they form an unpatterned group, unpatterned meaning not replicating in a predetermined manner except as determined by the shape of the object to be covered. Each of the drawings herein depict unpatterned or non-patterned contact areas. U.S. Pat. No. 6,286,145 illustrates patterned contact areas at FIG. 6, and is hereby incorporated by reference for comparative purposes.

[0023] The outer and inner layers are secured to each other in such a manner as to allow substantial relative movement between them in areas other than the contact areas. This allows wind to blow and move the outer layer relatively independent from the inner layer, dissipating energy better than single layer covers or multi-layer covers that are bound in a way that does not allow independent movement therebetween.

[0024] The outer layer 12 and the inner layer 28 are bound to each other in the preferred embodiment by a series of tabs 46 fixedly attached to both the outer seam 24 and the inner seam 36. These tabs are preferably each a short strip (1-3″) of durable material such as nylon that is sewn or otherwise bonded to the seams 24 and 36 at spaced locations dictated by the shape of the particular object 42 to be covered. Alternatively, the outer seam 24 and the inner seam 36 may be bonded together continuously, or may comprise a single seam that bonds the top outer panel 16, the side outer panel 22, the top inner panel 32, and the side inner panel 34 together. In the preferred embodiment, tabs 46 are used to maximize the allowable relative movement between the outer layer 12 and the inner layer 28. A series of spaced tabs 46 also bind the outer layer edge 26 to the inner layer edge 38 to prevent partial inversion of the outer layer relative to the inner layer. The layers 26 and 38 may also be removably attached to each other, such as with snaps or zippers.

[0025] The sum of the contact areas should be substantially less than the area of the interior surface 30 or of the inner layer 28 in order that the two layers may move relatively independent of each other. Substantially less as used herein means less than about 5%. In a preferred embodiment, the sum of the contact areas is less than about 2% of the area of the interior surface 30. In a most preferred embodiment, the sum of the contact areas is less than 1% of the area of the interior surface 30.

[0026] The preferred embodiment of the cover 10 includes at least one means for removably securing 48 the cover 10 to an object 42, the object being a table in FIGS. 1-2. The means for removably securing 48 each define a fixed end 50 (shown in FIGS. 3, 5 and 6) that is fixedly attached to the inner layer 28, and a free end 52 that includes a releasable fastener such as the hook and loop fastener (such as VELCRO™) depicted in FIG. 1. The releasable fastener may also include a drawstring as detailed in FIG. 2 for retention in a channel 54 defined by or attached to the inner layer 28, or an S-hook attached to the free end 52 as shown in FIG. 3 for attaching to another releasable fastener or to the object itself. The drawstring and S-hook examples make clear that the means for removably securing 48 need not secure directly to the object 42, but may instead partially envelop the object to prevent inadvertent removal of the cover 10. The means for removably securing 48 may also include a belt, buckle, tie or strip of material, snap, button, grommet, or any of the variety of known non-destructively removable fasteners.

[0027]FIG. 3 depicts in cross section a cover 10 according to the present invention affixed to a boat. The outer layer 12 is bound to the inner layer 28 at a common seam 58, though as depicted each layer is a single uninterrupted swath of material rather than a plurality of panels. In addition to the common seam 58, the outer layer 12 is fixed to the inner layer 28 by a plurality of spaced tabs 46 to prevent the outer layer 12 from blowing up and exposing the inner layer 28, which may or may not be waterproof. In this embodiment, the tabs 46 do not attach the outer layer edge 26 to the inner layer edge 38, but rather allow a flap of the outer layer 12 to fall freely. Portions of the inner layer 28 are pulled taught against the hull of the boat by the means for removably securing 48, S-hooks attached to each other. A gap between the outer layer edge 26 and the inner layer edge 38 allows increased air circulation between the layers 12 and 28 in this embodiment.

[0028]FIG. 4 illustrates a cover according to the present invention over a chaise, wherein the inner layer 28 is shown in dashed lines attached to the outer layer 12 at tabs 46. The inner top panel and the outer top panel are the same size and shape in FIG. 4. The inner layer 28 includes a top inner panel 32 that extends from an inner layer proximal edge 60 to an inner layer distal edge 62. When the top inner panel 32 is laid flat, the distance between these edges 60 and 62 defines the major span 18. The minor span 20 is the length of a line perpendicular to the major span 18. Where, for example, the major span is 10′ and the minor span is 2.5′, the perimeter around the inner top panel is ten times the minor span. Since the sum of the contact areas defined by the few tabs 46 is relatively small, an unbonded area defined as a continuous section of the inner top panel free of contact areas is slightly less than 25 ft². The relation of inner top panel perimeter (or inner layer perimeter where the cover is not comprised of panels) to unbonded area is a measure of the relative independence of movement between the layers. For example, a patterned bond spaced every two or three inches across the cover of FIG. 4 encompasses a relatively small area compared to the cover itself, but affords little relative movement between the layers. Instead, limits as to a continuous unbonded area free of contact areas within a certain perimeter assure proper movement between layers in order to better dissipate wind energy as compared to prior art covers.

[0029] Where the inner layer 28 is a circle of smaller size than the outer layer 12 as in FIG. 5, the contact site may be along the inner layer edge 38 by a single or double continuous line of stitches 64 or other bonding means known in the art and noted herein. Various means for removably securing 48 are fixed to the inner layer 28 as shown. Both the major span 18 and the minor span 20 are equal to the diameter of the inner layer 28. The minor span 20 is hereinafter referred to as x. The area of the unbonded area depicted in FIG. 5 is therefore slightly less than $\frac{1}{4}\pi \quad {x^{2}.}$

[0030] If an aperture for an umbrella were placed in the center of the cover 10, and the layers were bonded in that region to prevent water from pooling between them, the unbonded area would be reduced by ${\frac{1}{4}\pi \quad d^{2}},$

[0031] where d is the diameter of the aperture including the 1″ spacing from any actual bond or contact site (described above as the contact area). Proper movement between the layers yields a limit to this relationship of about x≧3 d. Practical applications find a limit at about x≧4 d for typical table sizes that would typically take an umbrella. Substituting geometrically yields unbonded areas of at least $\frac{2}{9}\pi \quad x^{2}$

[0032] and $\frac{15}{64}\pi \quad x^{2}$

[0033] respectively, and a perimeter in two lines (concentric rings) whose total length equals about 2.5 πx in the latter instance. To account for variations in the shape of the unbonded area (i.e. not a smooth circle due to contact site placement), the perimeter can be reasonablyexpanded to about 5.0 πx. Where the cover or top panel thereof is in the shape of an oval, a boat cover wherein the top panel is 20′ long and 4′ wide defines a single line perimeter with a length that is less than or equal to about 7.21 πx using a standard equation that estimates the perimeter of an oval without integrating. This can be reasonably rounded to 10 πx to account for less than a perfectly defined oval.

[0034]FIG. 6 is a cross section similar to FIG. 5 except the outer layer 12 and the inner layer 28 are the same size, and the outer layer edge 26 is bonded continuously to the inner layer edge 38. Both FIGS. 3 and 6 show explicitly that the means for removably securing 48 are fixedly attached only to the inner layer 28, and are not sewn through to the outer layer 12 in these embodiments. That is, the fixed end 50 of the means for removably securing 48 is not fixed at a contact site 44, but at a location spaced from a contact site.

[0035] While the preferred embodiment and several modifications have been shown and described, additional various changes and substitutions will be apparent to those skilled in the art and may be made without departing from the spirit and scope of the present invention. The embodiments described above are hereby stipulated as illustrative rather than exhaustive. 

What is claimed is:
 1. A removable cover for protecting an object from exposure to weather comprising: an outer layer defining an exterior surface; at least one inner layer defining an interior surface for contacting the object, wherein said inner layer is attached to said outer layer by at least one contact site such that said inner and outer layers are movable independently of each other except at the contact site; and means for removably securing said cover to the object, said means attached to said inner layer.
 2. The removable cover of claim 1 wherein said means for removably securing is attached only to said inner layer.
 3. The removable cover of claim 2 wherein said means for removably securing is selected from the group consisting of drawstring, belt, buckle, tie, hook-and-loop fastener, snap, button, grommet, and hook.
 4. The removable cover of claim 1 wherein an area of the interior surface is less than an area of the exterior surface.
 5. The removable cover of claim 1 wherein said inner layer comprises a plurality of patches, each patch being fixedly secured to said outer layer and positioned at a stress point defined by the object.
 6. The removable cover of claim 1 wherein the at least one contact site is along an edge of the inner layer.
 7. The removable cover of claim 1 wherein the at least one contact site is a plurality of contact sites spaced from one another.
 8. The removable cover of claim 1 wherein said outer layer is UV resistant.
 9. The removable cover of claim 1 wherein said inner layer is made from a polymeric material.
 10. The removable cover of claim 1 wherein the at least one contact site defines at least one contact area, the sum of the contact areas being substantially less than an area defined by the interior surface.
 11. The removable cover of claim 10 wherein the at least one inner layer is a durable single layer.
 12. A removable cover for shielding an object from exposure to weather, comprising: a UV resistant outer layer defining a top outer panel and at least one side outer panel fixedly attached to one another; at least one inner layer defining a top inner panel having a minor span x and at least one side inner panel, said inner layer attached to said outer layer by at least one contact site defining at least one contact area; wherein the top inner panel includes an unbonded area free of any contact area, said unbonded area defining an area of at least $\frac{2}{9}\pi \quad x^{2}$

and bounded by a perimeter defined by at least one line whose total length is no more than 7.21 πx.
 13. The removable cover of claim 12 wherein the top outer panel and the at least one side outer panel are fixedly attached to one another at a seam; and said at least one inner layer is fixedly attached to said outer layer by at least one contact site at the seam.
 14. The removable cover of claim 13 wherein said at least one inner layer is attached to the at least one side outer panel at a contact site.
 15. The removable cover of claim 12 further comprising means for removably securing said inner layer to the object, said means being fixedly attached only to the inner layer.
 16. The removable cover of claim 12 wherein the unbonded area defines an area of at least $\frac{15}{64}\pi \quad {x^{2}.}$


17. The removable cover of claim 12 wherein the perimeter of the unbonded area is defined by a single line having a length no more than 10.0 πx.
 18. The removable cover of claim 12 wherein the perimeter of the unbonded area is defined by at least one line whose total length is no more than 5.0 πx.
 19. The removable cover of claim 12 wherein the perimeter of the unbonded area is defined by at least one line whose total length is no more than 2.5 πx.
 20. An outdoor furniture cover comprising: an outer UV resistant layer including a top outer panel and at least one side outer panel fixedly attached to one another at an outer seam; at least one inner layer including a top inner panel and at least one side inner panel fixedly attached to each other at an inner seam; a plurality of discrete contact sites connecting said outer seam to said inner seam, said inner layer and said outer layer fixedly attached to one another only at said plurality of contact sites; and means for removably securing said cover to said outdoor furniture, wherein said means are attached to said inner layer.
 21. A method of covering at least one article of furniture comprising the steps of: providing a cover comprising an outer layer defining an exterior surface, at least one inner layer defining an interior surface for contacting the object, wherein said inner layer is fixedly attached to said outer layer by at least one contact site such that said inner and outer layers are movable independently of each other except at the contact site; and means for removably securing said cover to the object, said means attached to said inner layer; positioning the cover on at least one article of furniture; securing the cover to the at least one article of furniture via the means for removably securing that is attached to said inner layer. 